Method for making dished disk wheels



Aug. 20, l946- j D. R. CORNELL, 2,495,052

l METHOD FOR `MAKINGDISHED DISK WHEELS Filed Aug. 24, 1944 3 Sheets-Sheet l MMM mmm

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Aug- 2G, 1946. D. R. CRNELL, Y 2,406,062 n METHOD- FOR MAKING D'SHED DI'SK WHEELS Filed Aug. 24, 1944 s sheets-sheet 2 u j? f4 ..59 y filj l @ff @6 l 6 n ???-v 0 I -fv Patented Aug. 20, 1946 METHOD FOR MAKING DISHED DISK WHEELS Dana R. Cornell, East Chicago, Ind., assigner to Standard Forgings Corporation, Chicago, Ill., a corporation of Delaware Application August 24, 1944, serial No. 550,959

This invention relates to a method for making dished disk wheels, and particularly for making disk Wheels which are deeply dished.

The disk wheels to be produced by my method punching is meant a method wherein the work is turned intermittently and each hand hole is formed separately by a punching -tool mounted at an inclined angle in order to work on the dished surface to be punched. Multiple punchl 1 Claim. (Cl. Z9-159.01)

, 2 l ing, obviously, is much more economical, and, furthermore, the hand holes produced therebyare uniform in size and spacing, a result difficult to attain by index punching.

are tapered in thickness, radially, from an annu- 5 Flexing of the finished wheel takes place 'to a lar region outwardly of the hub portion to the maximum degree in the rirny portion which has peripheral edge of the disk, and are provided the largest circumference and least thickness. ywithfa plurality of hand holes located in the web Therefore, it is of particular importance to avoid portion between said hub portion and the periphweakening the rim region of the disk by cutting `eral edge. The disk, as initially forged, is relaoff metal on acute angles to form the necessary tively hat and is subjected to severe bending and hand holes. Excessive metal is cut away when forming `operations in order to produce the deeply the hand holes are punched out after the final dished disk wheels of my invention. shaping of the deeply dished disk and therefore By 'using the method hereinafter described, my method of punching the holes between the several important advantages are attained. The first and final forming operations serves several forged, relatively flat disk while still hot, is subpurposes: conserving the metal around the hand jected .to'trimming and preforming in one operaholes; preserving the right angle relationship of tion, punching of the central aperture and hand the cut edges and adjacent disk surfaces; miniholes in `another operation, and iinal forming in mizing the length of the stroke of the press rea third operation. By this method, vthe hand 9.0 quired for punching the holes before the disk lholes can be punched through the web of the has'beel'l giVGIl ts'deep (lished form; facilitating ldisk after it has been moderately bent and formed the punching by accomplishing it before the disk but `while it is still vfairly flat, and 4sufficient backhas become cool; and avoidingr distortion of the ing is afforded by a lower, supporting die to metal which would result if the major bends properly support the disk while it is beingr were formed in the disk after the punching operpunched. However, the major bends are placed ation. in .the disk in the rst forming operation, prior In the drawings; to `the punching, so that the final forming opera- Fig. lis a Vertical sectional view of a pair of tion does not .distort unduly the metal around ydies for preforming and trimming the relatively the hand holes, thus minimizing distortion in a dat forged disk. part of the disk which is particularly subject to Fig. 2 shows the apparatus of Fig. 1 in ano-ther load strains in operation. Although the disk is .position and shows the forged disk trimmed and deeply dished in the final forming operation, the preformed. major bends placed therein in the nrst forming Fie. 3 is `a vertical sectional View of punching operation are not greatly affected in said final apparatus, ShOWing the preformed disk after the forming step and this is a desirable feature of centra-l aperture and hand holes have been cut. my invention for the 'reason that the major bends Fig. 4 iS a Vertical SSCOIIQJ VBW 011 an enlarged should be accomplished while the disk `is still scaleof a part of a pair of dies for finally forms01iding the punched, preformed disk.

Punching of the hand holes between the `'first 40 Fig. A5 is a plan View of the finished disk. and final forming operations results in cut edge Fig. 6 is a transverse section, on an enlarged surfaces which are substantially at vright angles scale, taken inthe plane of the line 6 6 of Fig. 5, to the adjacent Vsurfaces of the disk instead of looking in the direction indicated by the arrows. forming acute angles as would be the case were In the preferred embodiment of theinvention the .hand holes punched after the final forming. shown in the drawings, the forged steel disk, as My method permits of the use of multiple punch shown in Fig. 1, is substantially flat andV smooth ing, whereas, if it were attempted after the final on its surface lll and provided with a central forming of the deeply dished disk, to produce boss ll. The oppositefsurface has a central boss hand holes of the form herein shown, index i2. a surrounding flat-.annular portion i3, thickpunching would have to be resorted to. By index cned annular portion l, radially inclined region i5 and .peripheral flat, narrow fin surface I6.

The apparatus 'for trimming and preforming .the forged disk, shown in Figs. l and 2, comprises dies I'l and i8. The die l1 is mounted in a suitable reciprocating support (not shown) and its face is complemental to the intended surface of one side of the disk in its preformed stage. Said die has a central recess I9, a flat annular surface 2U, a radially curved concentric ring 2|, two radially downwardly inclined'concentric surfaces 22 and 23 and a peripheral horizontally disposed surface 24. On the outer edge of the" surface 24 is a peripheral cutting edge 25 made of stellite, chromium or other suitable materialv welded on the carbon steel casting constituting the die I1. y

The lower forming die 8 is rigidly mounted on an anvil 26 having a fiat shoulder 21 on which is mounted, by a bolt 28, a circular housing 29 internally recessed at 39, toaccoinmodate a ring 3| between the housing 29 and the die I8. The ring 3| is supported on a plurality of coiled springs 32, located beneath the flanges of the ring adapted to move vertically in the recesses 30 of the housing 29. The ring 3| has a flat upper surface. j

The kface of the die IB is providedl with a central recess 34, surrounded by a flat annular surface 35, radially curved concentric ring 36 and radially-downwardly inclined portions 31 and 3S. The forged disk is placed on the lower forming die I8 with its fiat surface i0 adjacent the face of the die, and the central boss in the recess 34. In this position the disk surfaces i3, I4, l and I6 face the upper die as shown in Fig. 1 and the peripheral portion of the disk is engaged between the fiat peripheral surface 24 and the top of the ring 3|. As the die is moved downwardly, the Vengaging members 24 and 3| continue to clutch the disk and prevent wrinkling of the metal as the diameter and circumference of the disk are reduced in 'the preforrning operation.

4 hand holes, and a cutter 48 for cutting the central opening. It also is provided with a disk bearing member 49, spring pressed by the springs 50. Another disk bearing member 5|, preferably integral with the member 49 and also held down by the action of the springs 50 bearing on the part 49, bears on the peripheral portion of the disk vwhile the cutting takes place. l'Ihelower die 52 has an annular groove or opening 53 through which the cut out metal to form the holes 54 Ymay pass, and it has a central depressible member 55 supported by a spring 59 for cooperating with the cutter 48. The peripheral disk supporting member 5l cooperates with the upper die member 5| to hold the rim portion of the disk during the punching operation.

Because of the fact that the web region 31--43 (Fig. 2) vof the disk is relatively flat when the hand holes are punched (Fig. 3), the stroke of As'the cutter edge 25 meets a cutter edge 33 fixed In Fig. 2 is shown the preformed, trimmed,

moderately dished disk as it appears in section after the first forming operation'. In this form, the upper surface comprises the central boss 34,

flat annular hub portion 35, downwardly curved annular ring 35 in which is utilized ,the metal of the thickened portion I4v (Fig. 1), at radially downwardly inclined annular portion 3, downwardly curved annular ring 3 8 and circumferential rim portion 39. The lower surface of the preformed disk comprises the boss 49, and surfaces 4|, '42, 43 andA 44, which together with the upper surfaces described form a disk of substantially uniform thickness in the central hub portion including the inner major bend, and of gradually decreasing thickness in the region between said major bend and the peripheral edge 45.

While the preformed disk is still relatively flat in the region defined by the surfaces 31-43, between the bends 3S and 38,` it is subjected to a multiple punching operation in which the central bosses 34 and 40 and part of the surrounding portions 35-4| are cut out to form a hub center, and hand holes are cut through the web portion 3|`-43. I have shown eight hand holes but the number may vary,v usually between five and ten. In Fig. 3, I have shown punching apparatus for multiple punching, that is, for providing the central opening and the desired number of hand holes in one punching operation. The upper punching die 46 has cutters 41 for cutting the the cutters 41 and 48 may be relatively short.

Also, although the cutters move in vertical planes,

the cut edges of the diskare substantially at right angles to the adjacent disk surfaces at the end of the punching operation shown in Fig. 3, thereby avoiding the formation of acute angles in the finished disk.

The next and nal step of my process is shown in Fig. 4, where the preformed, trimmed and punched out disk is subjected to its final forming operation by upper and lower dies 58, 59 respectively. These dies have disk bearing surfaces complemental to the finished form of the deeply dished disk shown in section in Figs. 4 and 6, and in plan view in Fig. 5. In its nished form, said disk retains the preformed surfaces 35, 4|, 3S and 42, with the central portion cut away to form the opening 60, but radially outwardly of said preformed major bend 36-42, the web region 3'l-43 of the punched out disk is given another annularly located, radially extending bend 6| which shapes the metal between and surrounding the hand holes 54 and changes the angular position of the rim portion 38, 39, 44 (Figs. 2 and 3) to the position indicated at B2, 63, 64 and in Figs. 4, 5 and 6.

As best shown in Fig. 6, these operations `resultin forming a deeply dished disk with hand holes having cut edges 66 and 6l substantially at right angles to the adjacent surfaces of the rim region of the disk. It is essential to preserve this relationship of the metal surfaces particularly in the rim region of the disk which is relatively thin and subjected to the greatest flexing and strain in use. `By my apparatus'and method I avoid cutting away of metal and the forming of acute angles between the hand hole edges and adjacent surfaces, in addition to the advantage of using multiple punching as heretofore mentioned.

It will be understood from the foregoing that my method comprises the preforming and trimming of a disk initially forged relatively flat, to provide two annular major bends such as dened by the curved surfaces 36-42 and 39--44, with a relatively flat web portion between them, then subjecting the preformed disk to a multiple punching operation which cuts a` central opening in the disk and a pluralityof hand holes in the web portion between said major bends, and finally subjecting the preformed, trimmed and punched out disk to another forming operation in which an annular bend is made in the web portion as indicated at 5| in Fig. 5, between the preformed 'major bends, whereby the-an`gular disposition of the rim portion of the disk is altered, and the disk as a Whole is deeply dished, all without undue distortion of the metal, while retaining required strength and contour where needed in the finished disk.

Changes may be made in details of construction of the apparatus described without departing from my invention as set forth by the following claim.

I claim:

The method of making a deeply dishd disk Wheel having a relatively at hub center and axially dished web portions terminating in a cylindrical rim portion, which comprises the step of preforming a relatively at forged steel disk with an annular hub portion of substantially uniform thickness surrounded by an annular rim portion and a relatively thickened annular portion between the hub and rim portions, yieldably clamping the periphery of the rim portion while initially bending the disk axially at said thickened portion and utilizing the metal of said portion to make the thickness of the bend substantially conform with that of the hub portion, and also bending the peripheral rim portion as it gradually-slips from between the clamping means preventing wrinkling of the metal as the diameter and circumference of the disk are reduced, thus providing the disk with two axially curved concentric major bends connected by a frusto-conical web portion in the initial bending operation, simultaneously punching a central aperture in the hub center portion and a plurality of hand holes in the web portion, and iinally bending and axially curving the web portion while maintaining the concentric bends substantially as formed, whereby the disk is deeply dished and the periphery of the rim portion is disposed substantially at right angles to the hub portion.

DANA R. CORNELL. 

